Big changes to the trail rig

[stout22]

This is a teaser till I get time to post pictures.
The old trail bronco has been going through some major changes this past week.
With a LOT of help from Yeller ( he's done the lion's share) the old Bronco has been undergoing a transformation.
I've been talking about this for a while and finally got the nerve up to do it.
The picture is of a set of 2008 super duty axles I bought at the beginning of the year.

 

[Yeller]

Been a fun project

 

[Colo77Bronco]

I am running those axles on my project as well. We did some creative frame work on the front end to clear the pumpkin better. Really excited to someday get it done but you know how that goes.

 

[Yeller]

Finished pic

 

[sprdv1]

This is a teaser till I get time to post pictures.
The old trail bronco has been going through some major changes this past week.
With a LOT of help from Yeller ( he's done the lion's share) the old Bronco has been undergoing a transformation.
I've been talking about this for a while and finally got the nerve up to do it.
The picture is of a set of 2008 super duty axles I bought at the beginning of the year.

hell yeah.. gonna be bad azz man

 

[sprdv1]

Been a fun project

Look forward to the Pics..

 

[stout22]

After breaking several D44 axle parts I wanted a more robust setup. I was also fighting a poor front pinon angle so I got to looking at a high pinon solution.
I swapped for a high pinon 44 but after more thought I knew it was not the robust solution. Next logical solution is a high pinion D60.
I found a set of 2008 f250/350 axles locally. They were complete, including steering linkages and parking brake cables. Dana 60 front and Sterling rear. Beefy disc brakes all around

 

[stout22]

Yeller (aka Steve) had kept telling me when I was ready to do the swap let him know and we could get it done. I called him and told him about the purchase and we started planning dates we could work. He said we should have it knocked out in a week.
Remove the old D44 and 9", get new driveshafts made, rework the exhaust, 3-link the front, 4-link the back, rework the brakes, rework the drivelines, clearance the fenders inside and out. I had my doubts but he was confident.

 

[stout22]

We originally planned on doing the work in July to have it ready for OCBR but problems with parts delivery delayed those plans. They lost my DOM tubing 3 times!
By the time it finally showed up our original dates were passed. Did I mention they lost my DOM tubing 3 TIMES!
When I finally did get the DOM it was dropped off at the road at the end of my driveway. Good thing most thieves are lazy and couldn't pick up the heavy box.

 

[lilthom]

That's the axle combo I have under Burnie. It makes most everything seem doable.

 

[stout22]

Another part of the logistics is that there are only 614 miles between his house and mine.
That's nothing to get between friends.
Mrs. Yeller had supper ready for us when we pulled in

 

[stout22]

I started by cutting the extra brackets off the axles.
The big cast bracket for the radius arms were first to go but I left the top, flat area thinking we may be able to make use of them. I cut off of the sterling the shock brackets and leaf spring perches but was able to save them for possible reuse.

 

[stout22]

The actual teardown started on Friday, 11 Oct. We got both axles out and most of the removal completed.

 

[stout22]

Another key component that had to happen was the Sterling had to be rebuilt/re-geared.
Thanks to okorangebrnco (Levi) for getting that done.
The new axles have 5.38 gears and Yukon Grizzly lockers in both. Hopefully this combo will keep the Bronco road friendly with my C4 and 40" tires.

 

[Colo77Bronco]

That's the gearing I wanted but my Sterling Rear is a 2011 so they don't make anything more than 4.88 for that so I am stuck with 4.88s. Luckily my 10r80 is geared so low it should be OK. Your gonna love it!

 

[okorangebrnco]

I had a blast that day! A very much needed day away and out of the office. Still in shock how easy it went together.

 

[1969]

What’s your plan for the suspension? I bet cutting the brackets off that Dana 60 took a while ha!

 

[Yeller]

What’s your plan for the suspension? I bet cutting the brackets off that Dana 60 took a while ha!

Patience

 

[stout22]

What’s your plan for the suspension? I bet cutting the brackets off that Dana 60 took a while ha!

The brackets are a mess to deal with. I wasn't able to totally remove the ones at the knuckles.

 

[Madgyver]

following for sure....